In a first aspect, the present disclosure provides a method for making an inorganic thermoset resin, the method comprising:
The present disclosure further provides an inorganic thermoset resin obtainable by the method as defined in the first aspect of the disclosure.
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1. A method for making an inorganic thermoset resin, the method comprising:
mixing SiO2, H2O and a metallic hydroxide to form an alkaline aqueous solution with pH from about 10 to about 14 comprising a metallic silicate, wherein said metallic hydroxide generates a first metallic oxide in the aqueous solution;
adding aluminum oxide (Al2O3) and silicon oxide (SiO2) to the alkaline aqueous solution comprising the metallic silicate;
adding halloysite nanotubes (Al2Si2O5(OH)4) to the alkaline aqueous solution to form an Si—O—Al species; and
curing the alkaline aqueous solution to form the inorganic thermoset resin comprising a product of the metallic silicate and the Si—O—Al species.
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This application claims benefit of European Application Serial Number EP 15382423.0, filed Aug. 10, 2015, which is herein incorporated by reference in its entirety.
The present disclosure relates to methods for making fire resistant inorganic thermoset resins. Particularly, this disclosure relates to a method for making a fire resistant inorganic thermoset resin comprising adding metal oxides and halloysite nanotubes to an alkaline silicate solution.
Previous solutions to make inorganic thermoset resins included, for example, contacting potassium silicate solution, water, Al2O3, ZrO2 and kaolin. ZrO2 and kaolin are common fillers in geopolymeric resins. A gel is formed that finally forms the inorganic thermoset resin. Then, metakaolin in powder form is added to the thermoset resin to avoid shrinkage during the resin curing. Dissolution of metakaolin powder is not a straightforward step, since this powder has low solubility. Metakaolin needs to be dissolved for a predetermined period of time. This is a time consuming and expensive step (metakaolin needs to be finely dispersed in the alkaline solution and that involves a complex process using a special mixing apparatus). Moreover, since metakaolin has to be added in a certain % weight of the resin, the addition of metakaolin considerably increases the weight of the resin.
There is a need in the art for an improved method to make fire resistant inorganic thermoset resins which eliminates the step of addition of the anti-shrinkage filler metakaolin, while at the same time provides a fire resistant inorganic thermoset resin which does not shrink during the resin curing.
In a first aspect, the present disclosure provides a method for making an inorganic thermoset resin, the method comprising:
(a) mixing SiO2, H2O and a metallic hydroxide for generating an alkaline aqueous solution with pH from 10 to 14 comprising a metallic silicate, wherein said metallic hydroxide generates a first metallic oxide in the aqueous solution,
(b) adding aluminum oxide (Al2O3) and silicon oxide (SiO2) to the alkaline aqueous solution comprising a metallic silicate generated in step (a) and
(c) adding halloysite nanotubes (Al2Si2O5(OH)4) to the solution generated in step (b).
The present disclosure further provides an inorganic thermoset resin obtainable by the method as defined in the first aspect of the disclosure.
A first aspect of the present disclosure is a method for making an inorganic thermoset resin, the method comprising:
(a) mixing SiO2, H2O and a metallic hydroxide for generating an alkaline aqueous solution with pH from 10 to 14 comprising a metallic silicate, wherein said metallic hydroxide generates a first metallic oxide in the aqueous solution,
(b) adding aluminum oxide (Al2O3) and silicon oxide (SiO2) to the alkaline aqueous solution comprising a metallic silicate generated in step (a) and
(c) adding halloysite nanotubes (Al2Si2O5(OH)4) to the solution generated in step (b).
Halloysite is defined as an aluminosilicate clay mineral mined from natural geological deposits that is chemically identical to kaolin, but differs in its morphology by possessing a unique crystal structure which can, under proper geological conditions, facilitate the formation of hollow nanotubes rather than only a stacked plate-like structure as observed in kaolin. In the present disclosure, Halloysite nanotubes are referred interchangeably as halloysite nanotubes or HNT.
Halloysite nanotubes are abundant and cheap.
The present disclosure provides a simplified method to produce inorganic thermoset resins.
The present disclosure eliminates the need for metakaolin (anti shrinkage agent). Instead of kaolin, halloysite nanotubes are used.
Halloysite nanotubes have the same chemical formula as kaolin but have a different structural morphology. However, the mechanism of the reaction that liberates free —Si—O—Al-species is the same as described below for kaolin but, in addition, halloysite nanotubes prevent the geopolymer resin from cracking during and after polymerization (curing) of the resin, eliminating the need for metakaolin. Thus, methods of the present disclosure:
Halloysite nanotubes have a double functionality in the resin synthesis: (1) is part of the composition of the resin forming Si—O—Al species necessary for the proper formation of the geopolymeric resin; and (2) it also serves as filler eliminating the addition of metakaolin, which is time consuming, expensive and increases the weight of the geopolymer resin prior art.
Methods of the present disclosure eliminate the step of adding metakaolin and makes the production of the inorganic thermoset resin easier than existing solutions.
ZrO2 and kaolin are common fillers in geopolymeric resins. Additional mineral fillers such as metakaolin were added to inorganic thermoset resins to avoid shrinkage after curing the resin. The addition of metakaolin to the inorganic thermoset resins was not a simple process. Metakaolin is a powder that needed to be finely dispersed in order to be incorporated into the solution. This process was done by using a particular mixing apparatus and was very time consuming.
Moreover, the addition of metakaolin contributes to increasing the weight of the resin prepared.
Therefore, the synthesis should be simplified in order to make its production feasible at industrial scale.
The present disclosure is directed to the addition of halloysite nanotubes as nano-scale additive for inorganic polymer resins as well as a filler of the inorganic polymer thermoset resins.
In a second aspect of the present disclosure, in step (a) the metallic silicate is selected from the group consisting of silicate of an alkali metal, silicate of an alkaline earth metal and silicate of a transition metal and mixtures thereof.
In the second aspect of the present disclosure, the metal is selected from the group consisting of Na, K, Li, Ca, Mg and Fe.
In a third aspect of the present disclosure, in step (a) the concentration of the metallic silicate is between about 3 M and about 4 M.
In a fourth aspect of the present disclosure, in step (b) the first metallic oxide/SiO2 molar ratio is between about 0.08 and about 0.4.
In a fifth aspect of the present disclosure, in step (b) the first metallic oxide/Al2O3 molar ratio is between about 0.6 and about 15.
In a sixth aspect of the present disclosure, in step (b) the SiO2/Al2O3 molar ratio is between about 3.5 and about 100.
In a seventh aspect of the present disclosure, a second metallic oxide is added to the solution generated in step (b), wherein the second metallic oxide is an oxide of a transition metal.
In the seventh aspect of the present disclosure, the transition metal is Zr or Ti.
In the seventh aspect of the present disclosure, the second metallic oxide is added at a concentration of between about 1% and about 10% by weight with respect to the total weight of the aqueous solution.
In an eighth aspect of the present disclosure, in step (c) halloysite nanotubes (Al2Si2O5(OH)4) are added at a concentration of between about 2% and about 20% by weight with respect to the total weight of the aqueous solution.
In a ninth aspect, the present disclosure further provides an inorganic thermoset resin formed by the method as defined in the first aspect of the disclosure.
The curing of the inorganic thermoset resin according to the seventh aspect of the disclosure is carried out by heating at a temperature of between about 60° C. and about 80° C. for between about 1.5 hours and about 3 hours. The curing may be also carried out at ambient temperature for several hours, for example, about 24 hours.
The inorganic thermoset resin according to the seventh aspect of the disclosure has many applications in several fields. It could be used in aerospace field for aircraft and space vehicles. It could also be used in trains and automobiles, vessels and other transportation vehicles and by composite manufacturers. In fact, the resin could be incorporated in any industrially manufactured products or goods. The inorganic thermoset resin may be used as a resin in state-of-the-art fiber-reinforced inorganic polymer resin (FRIP) composites.
The outstanding fire resistance of the inorganic thermoset resin according to, for example, the seventh aspect of the disclosure up to 1000° C., makes it a very sought after product for applications where there are stringent fire resistance requirements. For example, in aircraft interiors.
The inorganic thermoset resin according to, for example, the seventh aspect of the disclosure can be used in any type of light weight fiber reinforced composites subjected to stringent fire resistance requirements. Although its application is certainly not restricted to aircraft applications, one high value application is in natural fiber reinforced composites in sandwich panels for aircraft interiors.
The inorganic thermoset resin according to the seventh aspect of the disclosure is obtained from natural nanoscale minerals and industry by products that are safe to produce and do not require specialized safety equipment, do not produce harmful chemical residues and are naturally fire resistant. The outstanding fire resistant properties of the inorganic thermoset resin of the disclosure are the result of its main ingredients being fire resistant themselves. This eliminates the need to apply or employ fire resistant additives in order to make the system fire resistant.
Methods of the present disclosure comprise preparing a stable alkaline aqueous solution. Solutions comprise a Potassium Silicate solution (K2SiO3) using the starting components SiO2, H2O and KOH. K2O is formed in the reaction from KOH.
Moreover, NaOH or any other suitable metallic hydroxide could be used to generate the corresponding metallic silicate as the alkaline silicate based medium which is necessary to obtain the geopolymeric resin.
The starting components are used as follows:
This solution reaches about pH=13.
(SiO2K2O. H2O═K2SiO3. H2O)
Then, water was added until a 3.5 M silicate K2SiO3 aqueous solution was generated.
Then, Aluminum oxide (Al2O3) and silicon oxide (SiO2) were added and mixed for 5 minutes.
In this step, the following molar ratios were used:
Then, Zirconium oxide (ZrO2) was added at a concentration of 4% by weight with respect to the total weight of the aqueous solution and mixed for 5 minutes.
Halloysite nanotubes (Al2Si2O5(OH)4) in 10% by weight with respect to the total weight of the aqueous solution were then added and mixed for 1 hour.
All of these processes were carried out at ambient temperature.
The inorganic thermoset resin was then cured at 80° C. for 2 hours.
The Boiling water test (BWT) is a test procedure known by the skilled person that determines whether a thermoset inorganic resin has undergone a correct polymerization and, therefore, if it has properly cured. The appropriate polymerization of the resin is crucial for the applicability of the resin so it could also be considered as a screening test before fine tuning any process development for inorganic thermoset resins.
The test consists of introducing small pieces of the cured resin in boiled water during 20 minutes. There are two possible scenarios:
To provide an accurate estimation of whether the samples suffer deformation and/or disintegration during such test, the diameter of the small pieces of cured resin samples subjected to the test are measured before and after the BWTs. This allows measuring any possible variation that the diameter of the cured samples could suffer at a millimeter scale.
Boiling Water Test Results:
Samples of the inorganic thermoset resin of the disclosure were subjected to the BWTs in order to assess if the resin had properly polymerized using. The resin successfully passed the BWTs since there was diameter resilience and no variation/disintegration of the samples was observed after immersing the samples in boiling water for 20 min. This indicates a correct polymerization/curing of the resin.
The inorganic thermoset resin's fire resistance was tested by subjecting 3 sandwich panels comprising outer skins made of flax fibers+inorganic thermoset resin of the disclosure, and a polyetherimide (PEI) foam as a core material to OSU test (Ohio State University test), which is the most stringent test to comply with fire requirements.
The OSU test is a method used to determine the Heat Release Rate from cabin materials exposed to radiant Heat (FAR 25, Appendix F part IV).
Summary of OSU Test
The specimen to be tested is injected into an environmental chamber through which a constant flow of air passes. The specimen's exposure is determined by a radiant heat source adjusted to produce the desired total heat flux on the specimen of 3.5 Watts/cm2, using a calibrated calorimeter.
The specimen is tested so that the exposed surface is vertical. Combustion is initiated by piloted ignition. The combustion products leaving the chamber are monitored in order to calculate the release rate of heat, which must be below 65 kW/m2.
Table 1 shows that the panels prepared with inorganic thermoset resin of the disclosure successfully passed the OSU tests.
The resin has excellent fire resistance, which makes it suitable for many applications, including, but not limited to, aircraft interiors.
TABLE 1
OSU tests results of the panels prepared using the inorganic
thermoset resin of the disclosure.
Total heat
Heat released after the first
Panel
released (kW/m2)
two minutes (kW * min/m2)
Panel 1
35.43 (a 72 s)
22.45
Panel 2
30.15 (a 56 s)
28.73
Panel 3
36.30 (a 67 s)
31.99
Values obtained
33.96
27.72
Threshold value
<65
<65
Gonzalez-Garcia, Ana, Lapena-Rey, Nieves, Martin-Alonso, Pedro Pablo, Martinez-Alonso, Amelia, Gonzalez-Rodriguez, Tomas
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